Brazing method

ABSTRACT

A brazing method is disclosed. The brazing method includes providing a substrate, providing at least one groove in the substrate, providing a support member, positioning the support member over the at least one groove in the substrate, providing a braze material, applying the braze material over the support member to form an assembly, and heating the assembly to braze the braze material to the substrate. Another brazing method includes providing a preform, providing a wire mesh, pressing the wire mesh into the preform, heating the preform to form a braze material including the wire mesh, providing a substrate, providing at least one groove in the substrate, applying the braze material over the at least one groove in the substrate, then brazing the braze material to the substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. Utility application Ser. No.14/041,701, filed on Sep. 30, 2013, and entitled “Brazing Method”, thedisclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention is directed to a brazing method. Morespecifically, the present invention is directed to brazing methods forforming cooling microchannels.

BACKGROUND OF THE INVENTION

Turbine systems are continuously being modified to increase efficiencyand decrease cost. One method for increasing the efficiency of a turbinesystem includes increasing the operating temperature of the turbinesystem. To increase the temperature, the turbine system must beconstructed of materials which can withstand such temperatures duringcontinued use.

In addition to modifying component materials and coatings, thetemperature capability of a turbine component may be increased throughthe use of cooling microchannels. The cooling microchannels can beincorporated into metals and alloys used in high temperature regions ofgas turbines. However, forming an exterior cover over the coolingmicrochannels can be difficult as thermal spraying directly over thechannel can result in coating material filling the channel. One methodto prevent the coating material from filling the channel includesfilling the channel with a sacrificial material prior to coating, thencoating the component and subsequently leeching out the sacrificialmaterial. The filling and removing of the sacrificial material can beboth difficult and expensive.

As an alternative to filling and leeching, a thin cover layer can bebrazed to the substrate, over the cooling microchannel. However, duringthe brazing of materials to a surface of the substrate, the brazingtemperatures required to sufficiently braze the material may also softenthe braze cover material. The softened material can sag or droop intothe cooling microchannels, blocking them as they harden. As such,brazing requires a very narrow temperature range, outside of which thecomponent can be damaged or made unusable.

A brazing method that does not suffer from one or more of the abovedrawbacks would be desirable in the art.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a brazing method includes providing a substratehaving at least one groove. Next, a support member is provided andpositioned over the at least one groove in the substrate. A brazematerial is provided and applied over the support member, the supportmember and the braze material forming a first braze assembly. Next, thefirst braze assembly is heated to braze the first braze assembly to thesubstrate.

In another exemplary embodiment, a brazing method includes providing apreform, providing a mesh, pressing the mesh into the preform, heatingthe preform to form a second braze assembly, providing a substrate,providing at least one groove in the substrate, applying the secondbraze assembly over the at least one groove in the substrate, thenbrazing the second braze assembly to the substrate.

In another exemplary embodiment, a brazing method includes providing abraze material, forming at least one groove in the braze material,securing support members within the at least one groove to form a thirdbraze assembly, providing a substrate, applying the third braze assemblyover the substrate, and brazing the third braze assembly to thesubstrate to form a brazed article. The at least one groove in the thirdbraze assembly forms at least one cooling microchannel in the brazedarticle.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart of a brazing method according to an embodiment ofthe disclosure.

FIG. 2 is a process view of a brazing method according to an embodimentof the disclosure.

FIG. 3 is a process view of a brazing method according to an embodimentof the disclosure.

FIG. 4 is a flow chart of a brazing method according to an embodiment ofthe disclosure.

FIG. 5 is a process view of a brazing method according to an embodimentof the disclosure.

FIG. 6 is a flow chart of a brazing method according to an embodiment ofthe disclosure.

FIG. 7 is a process view of a brazing method according to an embodimentof the disclosure.

FIG. 8 is a process view of a brazing method according to an embodimentof the disclosure.

FIG. 9 is a process view of a prior art brazing method showing a brazematerial forming a convex border within a groove in a substrate.

Wherever possible, the same reference numbers will be used throughoutthe drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

Provided is an exemplary brazing method. Embodiments of the presentdisclosure, in comparison to processes and articles not using one ormore of the features disclosed herein, increase efficiency of coolingmicrochannel formation, decrease cost of cooling microchannel formation,decrease encroachment of braze material into cooling microchannelsduring brazing, permit increased brazing temperatures, decrease scraprate during brazing, permit formation of cooling microchannels in thebraze material, or a combination thereof.

Referring to FIG. 1 and FIG. 2, in one embodiment, a brazing method 100includes providing a substrate 101 having at least one groove 103,providing a support member 105, positioning the support member 105 overthe groove 103 in the substrate 101 (step 110), providing a brazematerial 107, applying the braze material 107 over the support member105 (step 120) to form a first braze assembly 109 comprising the supportmember 105 and the braze material 107, and heating the first brazeassembly 109 (step 130) to braze the first braze assembly 109 to thesubstrate 101. In another embodiment, the braze material 107 may beformed with a thickness of up to 30 mils, up to 25 mils, up to 20 mils,or a combination thereof. The brazing is performed by any suitable brazemethod capable of securing the braze material 107 of the first brazeassembly 109 to the substrate 101 to form a brazed article. Each of theat least one grooves 103 in substrate 101 forms a cooling microchannel104 in the brazed article. Suitable braze methods include, but are notlimited to, vacuum brazing, atmospheric brazing, brazing in anon-oxidizing atmosphere, or a combination thereof. The braze material107 includes any suitable material such as, but not limited to, anickel-based braze alloy.

Referring to FIG. 3, in one embodiment, the first braze assembly 109also may be intermediate the substrate 101 having the groove 103, and asecond substrate 102 comprising the same material. In this embodiment,not only does the first braze assembly 109 prevent sagging, slumping, ordrooping of the braze material 107 into the groove 103, but the firstbraze assembly 109 joins the substrate 101 having the groove 103 to thesecond substrate 102. Referring to FIG. 9, sagging, slumping, ordrooping, as used herein, refers to the braze material 107 entering thegroove 103 and forming a convex border within the groove 103.

During the heating of the first braze assembly 109 (step 130), a brazetemperature softens the braze material 107, which otherwise may sag,slump, or droop into the groove 103 under its own weight withoutsupport. However, positioning of the support member 105 over the groove103 (step 110) maintains the braze material 107 above the groove 103,minimizing, reducing, or eliminating the sagging, slumping, or droopingof the braze material 107. Additionally, the support member 105 reducesor eliminates scrap formation from an application utilizing increasedheat to the braze material 107 by reducing or eliminating the sagging ordrooping of the braze material 107 into the groove 103. The supportmember 105 may be any suitable article capable of maintaining the brazematerial 107 above the groove 103 during the heating of the first brazeassembly 109 (step 130). Suitable articles for the support member 105include, but are not limited to, a rod, a wire, a mesh 201 (FIG. 2), asolid sheet, a perforated sheet, or a combination thereof. The supportmember 105 preferably should have a sufficiently high meltingtemperature to survive brazing. However, support member 105 may beincorporated into the brazed article or may degrade within the brazedarticle during the life of the turbine.

The positioning of the support member 105 over the groove 103 (step 110)to reduce or eliminate the slumping, sagging, or drooping of thesoftened braze material 107 permits brazing temperatures to be achievedwithout the braze material 107 entering the groove 103. In oneembodiment, the support member 105 may be assimilated into the brazematerial 107 by the increased brazing temperatures during the heating ofthe first braze assembly 109 (step 130). In one embodiment, the supportmember 105 has a higher melting and softening temperature thantemperature of the braze material 107 and is incorporated into a brazedarticle. The support member 105 that can withstand the heating of thefirst braze assembly 109 (step 130) includes any suitable compositionthat is not softened at brazing temperatures. Suitable compositionsinclude those that are similar or substantially similar to the substrate101, such as, but not limited to, ceramics, metal alloys, or acombination thereof. Support members that may degrade include materialsthat may oxidize during high temperature turbine operations, such assteel.

The cooling microchannel 104 forms between the substrate 101 and thefirst braze assembly 109. The cooling microchannel 104 includes an openinterior space to permit the flow of a fluid therein. Reducing oreliminating the sagging or drooping of the softened braze material 107into the open interior space of the cooling microchannel 104 permitsunimpeded flow of cooling fluid. In one embodiment, the coolingmicrochannel 104 includes a width and/or depth of, but not limited to,between about 5 mils and about 200 mils, between about 10 mils and about150 mils, between about 10 mils and about 100 mils, or any combination,sub-combination, range, or sub-range thereof wherein one mil equals0.001 inches. In another embodiment, the width and/or depth of thecooling microchannel 104 varies between channels or along the coolingmicrochannel 104 itself. In a further embodiment, the coolingmicrochannel 104 includes any suitable cross-sectional shape such as,but not limited to, a circle, a semi-circle, a square, a rectangle, anoval, a triangle, any other polygonal shape, or a combination thereof.

The substrate 101 includes any component utilizing the coolingmicrochannel 104 therein such as, but not limited to, a bucket, anozzle, a shroud, a hot gas path component, or combustor. In oneembodiment, the first braze assembly 109 is shaped prior to heating(step 130) to conform with the shape of the substrate 101 so that thefluid flowing through the cooling microchannel 104 does not leak. Thesubstrate includes any suitable brazeable composition such as, but notlimited to, a nickel-based alloy, a cobalt-based alloy, a high-strengthsteel alloy, or a combination thereof. In a gas turbine, the substrate101 having the cooling microchannel 104 is exposed to operationaltemperatures of between about 1600° F. and about 2400° F., between about1700° F. and about 2300° F., between about 1800° F. and about 2200° F.,or any combination, sub-combination, range, or sub-range thereof.Providing the braze material 107 having a similar or substantiallysimilar coefficient of thermal expansion to the substrate may reducestress from differential expansion during operation.

Referring to FIG. 4 and FIG. 5, in one embodiment, the mesh 201 ispressed (step 210) into a preform 203 in a “green” state prior asintering operation, then heated (step 220) to form a second brazeassembly 209. In another embodiment, the mesh 201 is pressed (step 210)in between two (2) or more layers of the preform 203 then heated (step220) to form the second braze assembly 209.

In one embodiment, prior to heating (step 220), the preform 203 in the“green” state forms a felt-type material. The preform 203 includes atleast a high-melting alloy, a low-melting alloy, and a binder. Inanother embodiment, both the high-melting alloy and the low-meltingalloy are in powdered form held together by the binder. Heating (step220) of the preform 203 sinters the preform 203, volatilizing or burningthe binder and securing the high-melting alloy, the low-melting alloy,and the mesh 201 to each other. The heating (step 220) is performed atany suitable temperature below the brazing temperature of the preform203, but sufficiently high to coalesce the high-melt alloy powder andthe low-melt alloy powder with minimal melting of the low-melt alloy.Additionally, in another embodiment, the heating (step 220) of thepreform 203 provides incipient melting of the low-melt alloy whichprovides for binding of the high melt alloy and mesh 201. Suitabletemperatures include, but are not limited to, between about 1700° F. andabout 2200° F., between about 1800° F. and about 2000° F., between about1850° F. and about 1950° F., or any combination, sub-combination, range,or sub-range thereof. The high-melting alloy may be similar orsubstantially similar to the substrate 101. The low-melting alloyincludes materials which melt below the high-melting material or thesubstrate, for example around 2000° F.

In one embodiment, the low-melting alloy has a composition characterizedby a nominal weight percentage of between about 8.0% and about 8.7% Cr,between about 9% and about 10% Co, between about 5.25% and about 5.75%Al, up to about 0.9% Ti (for example, between about 0.6% and about0.9%), between about 9.3% and about 9.7% W, up to about 0.6% Mo (forexample, between about 0.4% and about 0.6%), between about 2.8% andabout 3.3% Ta, between about 1.3% and about 1.7% Hf, up to about 0.1% C(for example, between about 0.07% and about 0.1%), up to about 0.02% Zr(for example, between about 0.005% and about 0.02%), up to about 0.02% B(for example, between about 0.01% and about 0.02%), up to about 0.2% Fe,up to about 0.12% Si, up to about 0.1% Mn, up to about 0.1% Cu, up toabout 0.01% P, up to about 0.004% S, up to about 0.1% Nb, and a balanceof nickel. In another embodiment, the low-melting alloy has acomposition characterized by a nominal weight percentage of about 19.0percent chromium, about 0.03 percent boron, about 10 percent silicon,about 0.1 percent carbon, and balance nickel.

In one embodiment, the high-melting alloy has a compositioncharacterized by a nominal weight percentage of about 12 percent cobalt,about 6.8 percent chromium, about 4.9 percent tungsten, about 1.5percent molybdenum, about 6.1 percent aluminum, about 6.3 percenttantalum, about 0.12 percent carbon, about 2.8 percent rhenium, about1.2 percent hafnium, and balance nickel.

The second braze assembly 209 is applied over the groove 103 in thesubstrate 101 (step 230) and brazed (step 240) to the substrate 101. Themesh 201 increases the rigidity of the second braze assembly 209,reducing or eliminating slumping, sagging, and/or drooping into thegroove 103 during the brazing (step 240). The brazing (step 240) of thesecond braze assembly 209 over the groove 103 forms a cover over thecooling microchannel 104 in the substrate 101. The mesh 201 remainswithin the second braze assembly 209 forming a portion of the brazedarticle, or is assimilated during the brazing or during subsequentoperation of the turbine (step 240). In one embodiment, the second brazeassembly 209 is shaped prior to brazing (step 240) to conform with theshape of the substrate 101 so that the fluid flowing through the coolingmicrochannel 104 does not leak.

Referring to FIG. 6 and FIG. 7, in one embodiment, at least one of thegrooves 103 is formed (step 310) in the braze material 107 and supportmembers 301 are secured (step 320) within the groove 103 in the brazematerial 107 to form a third braze assembly 309. In one embodiment, thesupport members 301 include the same material as the substrate 101, andhave a melting temperature above the brazing temperature of the brazematerial 107. The support members 301 are secured (step 320) in anysuitable position within the groove 103 to reduce or eliminate slumping,sagging, and/or drooping of the braze material 107 into the groove 103.Suitable positions include, but are not limited to, side portions 303 ofthe groove 103, a top portion 305 of the groove 103, or a combinationthereof.

After securing (step 320) the support members 301 within the groove 103,the third braze assembly 309 is applied (step 330) over the substrate101. The third braze assembly 309 is shaped prior to applying (step 330)to conform with the shape of the substrate 101 so that the fluid flowingthrough the cooling microchannel 104 does not leak. In one embodiment,when the third braze assembly 309 is applied (step 330), at least one ofthe grooves 103 in the third braze assembly 309 is positioned tocorrespond with at least one of the grooves 103 in the substrate 101.Together, the corresponding grooves 103 between the third braze assembly309 and the substrate 101 form the cooling microchannels 104. In anotherembodiment, when the third braze assembly 309 is applied (step 330), atleast one of the grooves 103 in the third braze assembly 309 ispositioned such that it does not correspond with the at least one groove103 in the substrate 101. Each non-corresponding groove 103 in eitherthe substrate 101 or the third braze assembly 309 forms a separatemicrochannel 104. In an alternate embodiment, the substrate 101 does notinclude the grooves 103. Applying (step 330) the third braze assembly309 over the substrate 101 without the grooves 103 permits the formationof the cooling microchannels 104 without forming the grooves 103 in thesubstrate 101.

Referring to FIG. 8, in an alternate embodiment, the support members 301include a single metal form positioned and/or secured within the groove103 in the braze material 107 to form the third braze assembly 309. Forexample, in one embodiment, the support member 301 is a microtube 311positioned within the groove 103. The microtube 311 has a higher meltingtemperature than the braze material 107, and is secured (step 320)within the groove 103 during the brazing (step 340) of the third brazeassembly 309 to the substrate 101. The microtube 311 secured within thegroove 103 forms the microchannel 104 in the brazed article. Themicrotube 311 includes any suitable shape such as, but not limited to,circular, square, rectangular, triangular, any other polygonal shape, ora combination thereof. In another embodiment, the shape and/or size ofthe microtube 311 is varied along the length of the microtube 311.

The support members 301 include any suitable material for maintainingthe shape of the groove 103 during the brazing (step 340). Suitablematerials include, but are not limited to, ceramics, metal alloys, or acombination thereof. For example, in one embodiment, the support members301 include ceramic, and are not brazed (step 340) to the substrate 101during the elevated temperature brazing (step 340). In another example,the support members 301 include metal alloys and both the braze material107 of the third braze assembly 309 and the support members 301 arebrazed (step 340) to the substrate 101 during the elevated temperaturebrazing (step 340).

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

What is claimed is:
 1. A brazing method, comprising: providing a brazematerial; forming at least one groove in the braze material; securingsupport members within the at least one groove to form a braze assembly;providing a substrate; applying the braze assembly over the substrate;and brazing the braze assembly to the substrate to form a brazedarticle; wherein each of the at least one grooves forms a coolingmicrochannel in the brazed article.
 2. The brazing method of claim 1,comprising maintaining the braze material above the at least one groovewithout the braze material entering the groove and forming a convexborder.
 3. The brazing method of claim 1, wherein the braze materialcomprises a nickel-based braze alloy.
 4. The brazing method of claim 1,wherein the braze material includes a coefficient of thermal expansioncompatible with the coefficient of thermal expansion of the substrate.5. The brazing method of claim 1, comprising selecting the supportmembers and the substrate to be made of a common material, the commonmaterial having a melting temperature above a brazing temperature of thebraze material.
 6. The brazing method of claim 1, comprising shaping thebraze assembly to conform with a shape of the substrate prior toapplying the braze assembly over the substrate.
 7. The brazing method ofclaim 1, wherein the cooling microchannels are formed without grooves inthe substrate.
 8. The brazing method of claim 1, wherein applying thebraze assembly over the substrate comprises positioning at least one ofthe grooves in the braze material to correspond with at least one grooveformed in the substrate.
 9. The brazing method of claim 1, whereinapplying the braze assembly over the substrate comprises positioning atleast one of the grooves in the braze material to not correspond with atleast one groove in the substrate such that a separate microchannel isformed by the at least one groove in the braze material or the at leastone groove in the substrate.
 10. The brazing method of claim 1, whereinthe brazing comprises vacuum brazing.
 11. The brazing method of claim 1,wherein the brazing comprises atmospheric brazing.
 12. The brazingmethod of claim 1, wherein the substrate comprises a nickel-based alloy.13. The brazing method of claim 1, wherein the substrate comprises acobalt-based alloy.
 14. The brazing method of claim 1, wherein thesupport members are ceramics.
 15. The brazing method of claim 1, whereinthe support members are microtubes.
 16. The brazing method of claim 15,wherein the microtube forms the microchannel in the brazed article. 17.A brazing method, comprising: providing a braze material; forming atleast one groove in the braze material; securing support members withinthe at least one groove to form a braze assembly; providing a substrate;applying the braze assembly over the substrate; and brazing the brazeassembly to the substrate to form a brazed article; wherein each of theat least one grooves forms a cooling microchannel in the brazed article;and wherein the securing of the support members includes arranging anddisposing the support members to reduce at least one of slumping,sagging, and drooping of the braze material into the groove during thebrazing of the braze assembly to the substrate.
 18. The brazing methodof claim 17, comprising shaping the braze assembly to conform with ashape of the substrate prior to applying the braze assembly over thesubstrate.
 19. A brazing method, comprising: providing a braze material;forming at least one groove in the braze material; securing supportmembers within the at least one groove to form a braze assembly;providing a substrate having at least one groove formed therein;applying the braze assembly over the substrate; brazing the brazeassembly to the substrate to form a brazed article; and maintaining thebraze material above the at least one groove without the braze materialentering the groove and forming a convex border; wherein each of the atleast one grooves forms a cooling microchannel in the brazed article.20. The brazing method of claim 19, wherein applying the braze assemblyincludes positioning at least one of the grooves in the braze materialsuch that it does not correspond with the at least one groove formed inthe substrate, each non-corresponding groove in the braze material andthe substrate forming a separate cooling microchannel.